Troy-Bilt Bronco J609, Operator'S Manual

Page 1: ... arrester meeting applicable local or state laws if any If a spark arrester is used it should be maintained in effective working order by the operator In the State of California the above is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands A spark arrester for the muffler is available through your nearest en...

Page 2: ...er Support Department or an authorized service dealer Copy the model number here Copy the serial number here CUSTOMER SUPPORT PleasedoNOTretumthe unit to theretailer from whereit waspurchased withoutfirstcontactingCustomerSupport If you have difficulty assembling this product or have any questions regarding the controls operation or maintenance of this unit you can seek help from the experts Choos...

Page 3: ...r repair to protect your eyes Thrown objects which ricochet can cause serious injury to the eyes 9 Wear sturdy rough soled work shoes and close fitting slacks and shirts Loose fitting clothes and jewelry can be caught in movable parts Never operate this machine in bare feet or sandals 10 Be aware of the mower and attachment discharge direction and do not point it at anyone Do not operate the mower...

Page 4: ...n steep slopes 5 Do not mow on wet grass Reduced traction could cause sliding 6 Do not shift to neutral and coast downhill Over speeding may cause the operator to lose control of the machine resulting in serious injury or death 7 Do not tow heavy pull behind attachments e g loaded dump cart lawn roller etc on slopes greater than 5 degrees When going down hill the extra weight tends to push the tra...

Page 5: ...the blade disengagement control If the blades do not stop within the this time frame your unit should be serviced professionally by your Troy Bilt dealer 4 Check brake operation frequently as it is subjected to wear during normal operation Adjust and service as required 5 Check the blade s and engine mounting bolts at frequent intervals for proper tightness Also visually inspect blade s for damage...

Page 6: ...with a slope in excess of 15 degrees a rise of approximately 2 1 2 feet every 10 feet A riding mower could overturn and cause serious injury If operating a walk behind mower on such a slope it is extremely difficult to maintain your footing and you could slip resulting in serious injury Operate RIDING mowers up and down slopes never across the face of slopes O ...

Page 7: ...seat spacers with the slots in seat pivot bracket Slide seat in until front seat spacer engages the seat stop See Figure 3 _ WARNING Before operating stand behind the machine and pull back on seat until fully engaged into stop Seat Stop Pivot Figure 2 IMPORTANT The shipping brace must be removed and discarded before operating your riding mower Locate the shipping brace and accompanying warning tag...

Page 8: ...ollow the instructions and operate the controls properly _ F _ G H A B C K L Figure 4 A PTO Blade Engage Lever H Cruise Control Button B Choke Control Super Bronco only I Ignition Switch C Parking Brake Button J Brake Pedal D Shift Lever K Drive Pedal E Cup Holder L Cargo Net notshown F Systems Indicator Monitod Hour Meter M Deck Lift Lever G Throttle Control Lever NOTE Any reference in this manua...

Page 9: ... Depress the drive pedal with your right foot when the tractor shift lever is in either forward or reverse to cause the tractor to move The further down the pedal is depressed the faster the tractor will travel The pedal will return to its original position when it is not depressed sToP This may also be referrred to as simply PTO lever PTO Blade Engage Lever Engaging this lever transfers power to ...

Page 10: ...ry is in need of a charge or that the engine s charging system is not generating sufficient amperage Refer to Batteryon 17 of this manual for charging procedure or have the engine s charging system checked by anauthodzed dealer Ammeter if equipped The ammeter measures the electrical output of the engine s charging system Under normal operating conditions with engine at full throttle the ammeter sh...

Page 11: ...afety interlock system prevents the engine from cranking or starting unless the parking brake is engaged and the PTO lever is in the Blades Stop position If this system should ever malfunction do not operate the tractor immediately contact a Troy Bilt dealer The safety interlock system will automatically shut off the engine if the operator leaves the seat before engaging the parking brake The safe...

Page 12: ... the blades are engaged place the PTO lever in the Blades Stop position 2 Turn the ignition key counterclockwise to the OFF position 3 Remove the key from the ignition switch to prevent unintended starting Dr v n Tractor Depress the brake pedal to release the parking brake Move the throttle lever into the FAST rabbit position To move forward place the shift lever in the FORWARD position then slowl...

Page 13: ...ct or a thrown object injury keep bystanders helpers children and pets at least 75 feet from the machine while it is in operation Stop machine if anyone enters the area Side Discharge To operate the cutting deck for side discharge of grass clippings only remove the mulch plug by unthreading the plastic wing nut which fastens it to the cutting deck This will allow the clippings to discharge out the...

Page 14: ...te the distance 4 The measurement taken in front of the axle should be between 1 16 and 5 16 less than the measurement taken behind the axle Adjust if necessary Leveling the Deck NOTE Check the tractor s tire pressure before performing any deck leveling adjustments Refer to Tires later in this section for further information regarding tire pressure FrontTo Rear The front of the cutting deck is sup...

Page 15: ...ieved _WARNING Never attempt to adjust the brakes while the engine is running Always disengage PTO move shift lever into neutral position stop engine and remove key to prevent unintended starting If the tractor does not come to a complete stop when the brake pedal is completely depressed or if the tractor s rear wheels can roll with the parking brake applied the brake is in need of adjustment The ...

Page 16: ...cted in the engine manual 6 Perform the above steps in the opposite order after oil has finished draining Refill the engine with approximately 62 oz 1 8 liters of new motor oil Air Cleaner Service the pre cleaner if so equipped and cartridge as instructed in the engine manual at the end of this manual SparkPlug Clean the spark plug and reset its gap once a season preferably at the start of each mo...

Page 17: ...T Never exceed the maximum inflation pressure shown on the sidewall of the tire The recommended operating tire pressure is approximately 10 psi for the rear tires and 14 psi for the front tires Refer to the tire sidewall for exact tire manufacturer s recommended or maximum psi Do not overinflate Uneven tire pressure could cause the cutting deck to mow unevenly The battery is sealed and maintenance...

Page 18: ... negative post of the good battery 8 Disconnect the positive jumper cable from the positive post of the good battery 9 Disconnect the other end of the positive jumper cable from the formedy dead battery Two fuses are installed in your tractor s wiring harness to protect the tractor s electrical system from damage caused by excessive amperage If the electrical system does not function or your tract...

Page 19: ...ends of the blades along the cutting edges parallel to the trailing edge at a 25 to 30 angle See Figure 14 If the cutting edge of the blade has already been sharpened to within 5 8 of the wind wing radius or if any metal separation is present replace the blades with new ones See Figure 14 IMPORTANT Each cutting blade edge has to be ground equally to maintain proper blade balance A poorly balanced ...

Page 20: ...deck to relieve tension on the deck belt 6 Remove the belt from around all pulleys including the deck idler pulley 7 Route the new belts as shown in Figure 15 Remount the belt guards removed earlier TransmissionDrive 8e t NOTE It is recommended that both drive belts be replaced at the same time 1 Remove the cutting deck as instructed earlier in this section 2 After disconnecting the battery cables...

Page 21: ...ttery tray opening Bracket 4 Remove the rear idler pulley from the double idler bracket Hole while unrouting the belt from around both the rear and the _ Id_er Adjuster Rod front idler pulley See Figure 16 5 Remove the hex bolt from the center of the engine puitey and gently lower it off the engine crankshaft Be careful not to lose any washers or spacers which may be on top of the 7 _ e engine pul...

Page 22: ...WARNING Drain fuel only into an approved container outdoors away from an open flame Allow engine to cool Extinguish cigarettes cigars pipes and other sources of ignition prior to draining fuel Follow instructions in the Seasonal Storage section of the engine manual for proper engine care prior to storing your tractor It is not necessary to remove the battery from the tractor for storage However cl...

Page 23: ...gas 6 Replace air cleaner cartridge or clean pre cleaner if so equipped Engine overheats 1 Engine oil level low 1 Fill crankcase with proper capacity and weight of oil 2 Air flow restricted 2 Clean grass clippings and debris from around the engine s cooling fins and blower housing Engine hesitates at high 1 Spark plug gap too close 1 Remove spark plug s and reset the gap at 030 RPM Idles poorly 1 ...

Page 24: ...r to the list of color codes below Please add the applicable color code to the part number for a replacement part For instance ifa part numbered 700 xxxx is painted Red the part number to order would be 700 xxxx 0638 Red 0638 Oyster Gray 0662 Powder Black 0637 A 27 4 1 20 24 ...

Page 25: ...le 9 style 38 710 1611B Cable Tie 3 16 x 05 x 7 4 39 726 3046 Choke Knob Cable Model LTX 2146 40 736 0119 Hood 9 style 41 726 0201 RH Side Panel 9 style 42 736 3078 LH Side Panel 9 style 43 710 1238 Headlight Lens 9 style 44 747 04158 Hood Hinge Rod 747 04161 Headlight Assembly 45 735 04023 Self tapping Screw 5 16 12 x 75 46 726 04029 Fuel Cap 47 731 2228 Fuel Tank Three Gallon 629 0469A Ignition ...

Page 26: ...of color codes below Please add the applicable color code to the part number for a replacement part For instance if a part numbered 700 xxxx is painted Red the part number to order would be 700 xxxx 0638 Red 0638 Oyster Gray 0662 Powder Black 0637 27 46 6 43 26 26 ...

Page 27: ...e Bearing Lift Cable 16 16 LTX 1842 Lift Cable 15 62 LTX 2146 Lift Handle Roller Pulley Lift Arm Re Pa_ No No 26 783 0720A 27 710 0260A 28 710 0604A 29 736 0331 30 720 04009 31 738 04012 32 736 3078 33 783 1010A 34 783 04314 35 783 1489 36 738 0296 37 726 0201 38 783 0209A 39 757 04001 40 735 0672 41 735 0673 42 726 3046 43 714 0111 44 783 04081 45 736 0204 46 731 0511 47 731 1990 48 731 2104B 49 ...

Page 28: ... list of color codes below Please add the applicable color code to the part number for a replacement part For instance if a part numbered 700 xxxx is painted Red the part number to order would be 700 xxxx 0638 Red 0638 Oyster Gray 0662 Powder Black 0637 14 10 28 ...

Page 29: ... Bearing 5 8 Shoulder Spacer 38 ID Steering Wheel Soft Grip Three Spoke Steering Wheel Cover Ref No 25 26 27 28 29 36 32 33 34 35 36 37 38 39 46 PaN No 638 0019A 638 0021 638 0020A 638 0022 719 0399B 719 0525B 712 0431 714 0162 726 0214 726 0341 736 0430 736 0331 738 1011 710 0643 634 04086 634 04081 734 0255 734 1731 741 0516A 741 0990A 734 2290A 783 0653F 738 0143 736 3004 Description LH Axle As...

Page 30: ... IMPORTANT For a proper working machine use Factory Approved Parts V belts are designed to engage and disengage safely A substitute non OEM V belt can be dangerous by not disengaging completely 71 35 24 9 55 6 57 4 3O ...

Page 31: ...acket Center Brake Control Assembly Speed Control Assembly Drive Pedal Assembly TT Screw 5 16 18 x 0 875 AB Screw 5 16 12 x 0 75 LD Screw 5 16 18 x 0 75 Ref No 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 Part No 719 1611B 711 04159 712 0130 712 3094A 714 0194 726 04928 732 0335 732 0955 732 0963 735 0662 735 3049 736 0262 ...

Page 32: ...ModelsJ609 T609 5 4 10 16 9 11 21 19 28 29 26 27 25 32 ...

Page 33: ...ing Screw 1 4 20 x 1 625 Upper Housing Input Shaft Needle Bearing 625 x 813 x 495 14 tooth Bevel Pinion Retaining Ring 437 Sleeve Bearing 75 x 1 0 x 1 0 Seal 75x 1 0x 125 Differential Assembly Flange Bearing 5 8 x 3 4 x 3 4 42 tooth Bevel Gear 42 tooth Bevel Gear Clutch Collar Flat Washer 70 x 1 125 x 031 Drive Shaft Thrust Washer 1 0 x 632 x 0 Flange Bearing 5 8 x 3 4 x 15 16 Detent Shaft Assembl...

Page 34: ...w Please add the applicable color code to the part number for a replacement part For instance if a part numbered 700 xxxx is painted Red the part number to order would be 700 xxxx 0638 Red 0638 Oyster Gray 0662 Powder Black 0637 A 10 48 NOTE 63 battery hold down rod is not shown in picture 34 ...

Page 35: ... 45 46 47 48 49 50 51 52 53 54 55 56 Part No 732 04035 723 0444 738 1020 736 0407 712 0459 783 1031A 783 0349 725 1426 710 0599 736 0222 683 0304C 725 1737A 725 1706A 710 0751 712 0271 712 3044 732 1165 710 3180 750 0596 710 3029 736 0171 736 0322 756 0982B 754 0497 783 0653F Description Compression Spring 1 28 x 3 125 Battery Strap Shoulder Screw 625 x 5 7 16 20 Bell Washer 45 x 1 0 x 062 Flange ...

Page 36: ...nsion Oil Drain Cap Muffler Bracket ModelT609 22 1 0 18 36 Ref No 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Part No Description 710 0227 710 0599 710 0726 710 1237 710 1314A 710 1315 712 0271 712 3017 721 0331 721 0460 725 0157 726 0205 736 0300 737 0169 751B221535 751 0535 751 0564A 751 0616A 751 0650A 751 0651A 751 3140 751 3141 751 3142 783 0615B 783 0625C AB Screw 38 18 x...

Page 37: ...ModelsJ609 T609 SYSTEMS tNIICATOR MONITOR t J I I 37 ...

Page 38: ...codes below Please add the applicable color code to the part number for a replacement part For instance if a part numbered 700 xxxx is painted Red the part number to order would be 700 xxxx 0638 Red 0638 Oyster Gray 0662 Powder Black 0637 22 23 32_i 58 10 _ 8 47 16 38 ...

Page 39: ...6 6932A 39 683 0446 40 754 0498 41 756 0627B 42 756 1262 43 710 1836 44 746 0976 45 783 1291 46 711 1534 Description Flat Washer 64 x 1 0 x 12 Bell Washer 265 x 75 x 062 Shoulder Screw 498 x 1 53 Bearing 625 x 1 574 x 470 Blade Star Center 21 23 Deck Release Pin Shoulder Spacer 625 x 324 Spacer 635 x 88 x 1 72 Deck Brake Assembly Deck Belt idler Pulley 3 5 Double Pulley 5 0 Self tapping Screw 1 4 ...

Page 40: ...ments and normal deterioration of the exterior finish due to use or exposure d Service completed by someone other than an authorized service dealer e Troy Bilt does not extend any warranty for products sold or exported outside of the United States its possessions and territories except those sold through Troy Bilt s authorized channels of export distribution f Replacement parts that are not genuin...